GoPro and DJI Osmo Housing
Background
Made in part with Ikelite, this prototype housing was 3-D printed using a SLA type printer (Formlabs 3), and made with pre-purchased Ikelite parts. The purpose of this design was to experiment with a housing design that would accept two different cameras. Not nessecarily at the same time, however, it would allow anyone with both the GoPro Hero 7, and the DJI Osmo to only purchase one housing. Along with being a cool part, it also allows less manufacturing for two different (but very similar) point and shoot cameras.
The Challenge:
To create an extremely pressure resistant casing to house a GoPro or a DJI Osmo. To allow any free-diver to take these common point and shoot cameras to a depth of 300ft.
My Role:
I collaborated with the Vice President of Ikelite to find a solution to this complex housing problem. With the assistance, I helped streamline the manufacturing process used at the company.
Process
This project was fairly complex in execution. The camera housing that I created is revolutionary compared to housings that have been made in the past. Normally, camera housings are molded, and then holes and smaller features are cut on a CNC machine. This housing was a ways different in the sense that it completely got rid of the actual molding process. This allowed for the housing to be completely developed in-house. To start, I first had to model up the GoPro Hero 7, and the DJI Osmo. I was lucky enough to actually have both of those physical models on hand, specifically from my employer. I used measurement instruments such as an optical comparator to determine the radii, and the physical dimensions on the outside of the part. After successfully modeling each and every dimension on the parts of the housing, I then overlaid the actual cameras by their focal points. This allowed me to actually make a housing that was able to fit both of the cameras after using the mold tool. After making the mold tool, I took the back off of the solid piece. This then allowed a back port to put the cameras in that was molded to shape for the cameras. The various shapes and sized were accounted for, and this allowed for these two different shaped and sized cameras to sit in the housing. As seen in the photo, the housing was actually 3D printed, and this allowed for a rapid prototype. This prototype was then tapped, which allowed for pre-made buttons to be placed on the actual housing. This ended up looking fairly nice. The aesthetic portion of the actual design was meant to look “aggressive” where mostly 90 degree angles were avoided. This also had a secondary function of making the part easier to machine, as there are no 90 degree corners.
Final Outcomes
This housing unfortunately never made it to market. I eventually ran out of time during my internship, and due to budget limitations I could not be hired full time at Ikelite. If I had more time on this project, I believe I would have been able to actually finish the design, creating a nominal solution for this problem.
Full Assembly View